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Understanding Ultrasonic Plastics Assembly Ultrasonic Plastic Assembly All Rights reserved. No part of this book may be reproduced or transmitted in any form without the written consent of the author or publisher. First Edition : December 1998 Web Edition : May 2011 For Private Circulation Published by - nevik sales & services, mumbai 400 098 Printed at - Anitha Arts Printers, Mumbai 400 055 PREFACE Ultrasonic Plastic Assembly is commonly used in many countries around the world, but in India it is still not as popular. Indian plastic processors seem to fear Ultrasonics -- too critical, too technical, too expensive, too difficult, .......... This fear, born perhaps out of an unhappy initial experience when trials conducted on existing products assembled by conventional methods did not meet expectations, is unjustified. Had the trials been conducted correctly -- after understanding the specific needs of Ultrasonics -- their experience would surely have been happier, and there would perhaps be many more users in India today. This book is intended to help processors Understand Ultrasonic Plastic Assembly, so they do things right the first time around, and succeed. It covers topics from Basic Principles of Ultrasonics, Ultrasonic Techniques, Compatibility of Plastics and related Properties, Part & Joint Design, Equipments, Toolings (Horns & Fixtures) to Troubleshooting Applications, Sources of Supply world- wide, and Safety in Ultrasonics. As production volumes increase and specs get tougher, weld consistency will become increasingly important. A poorly welded part is quite likely to fail prematurely, and this is simply unacceptable in todays highly competitive business environment. Ultrasonic Plastic Assembly is a clean, consistent and reliable process that holds promise for the processor seeking to produce larger volumes, with improved quality, at reduced costs. While initial costs may appear high, the benefits -- tangible and intangible -- far outweigh these. Better Quality, Higher Productivity and Lower Costs -- could you ask for more ? Switch to Ultrasonic Plastic Assembly, and enjoy the Benefits. Good Luck ! ABOUT THE AUTHOR Mr Vinoo Kumar is a Mechanical Engineer, with vast experience in marketing Capital Goods. He has been actively involved in Plastics Assembly for close to 30 years -- primarily Ultrasonic Plastic Assembly. During this period he has assisted numerous users switch from subjective, labour- intensive methods to semi-automated, consistent and reliable methods such as Hot Plate, Ultrasonic & Vibration welding methods. His close interactions with users and leading companies worldwide has given him an overall perspective in plastic assembly methods, and he shares his hands- on experiences in this book. His business venture -- nevik ultrasonics -- accepts Job Work (for Ultrasonic Welding), designs, manufactures and supplies Ultrasonic Horns & Fixtures, and offers several Technical Services, including sourcing Ultrasonic Plastic Welding Equipment, Troubleshooting Applications, Training and other such technical support. His e-mail address is [email protected] ACKNOWLEDGEMENTS In compiling this book, reference has been made to literatures published by leading companies worldwide, particularly Mecasonics KLN, France King Ultrasonics, Taiwan Bielomatik, Germany Sonobond Ultrasonics, U.S.A. PFAFF, Germany Sonics & Materials, U.S.A. Reliance India Ltd, India Branson Ultrasonics Corporation, U.S.A. G E Plastics, India Mobay Chemical Corporation, U.S.A. Seidensha Electronics Co. Ltd. Japan Ultra Sonic Seal, U.S.A. Toray Plastics, Malaysia Dukane Ultrasonics, U.S.A. G E Plastics, Netherlands IPCL,Mumbai Leister Elektro, Switzerland Gharda Chemicals, Mumbai We gratefully acknowledge their support. understanding Ultrasonic Plastic Assembly Contents Chapter Description Page 1 Introduction 1 The Options Today 1 The Benefits 3 Success 4 Applications & Market Segments 5 2 Basic Principles 7 Ultrasonics 7 Principles of Ultrasonics 8 The System Elements 9 3 Assembly Techniques 14 Welding 14 Insertion 20 Staking 22 Swaging & Forming 26 Cutting & Sealing 27 4 Plastics 30 Compatibility of Plastics 33 Variables affecting Ultrasonic Processing 36 Physical Properties of Plastics 39 5 Part & Joint Design for Ultrasonics 51 The Energy Director 53 The Shear Joint 58 Other Considerations 60 Chapter Description Page 6 Equipments 63 The Range 63 Automation 67 Selection Aids 69 7 Toolings 73 Horns 73 Fixtures 81 8 Troubleshooting Applications 83 Welding 85 Staking 93 Insertion 95 9 Safety in Ultrasonics 99 High voltage 99 Pressure/Force 99 Ultrasonics 100 Environment 101 Equipment Safety 101 10 Sources of Supply 103 India 103 Far East 104 Europe 105 USA 106 11 Glossary 107 Technical Terms & Meanings 107 Chapter 1, Introduction 1 Chapter 1 - Introduction THE OPTIONS TODAY When you wish to Join Thermoplastics, you may choose from 12 options 1 Mechanical Fasteners (screws, nuts & bolts, rivets) 2 Press & Snap Fits 3 Solvent Bonding 4 Adhesive Bonding 5 Heat Sealing, also known as Impulse Sealing (when used for films) Hot Plate (when used for moulded parts) Hot Mirror (when used for pipes) Hot Wedge (when used with films, fabrics & geo-textiles) Hot Sword (when used for sheets) 6 Hot Air Welding 7 Radio Frequency Welding 8 Spin Welding 9 Electro - Magnetic Welding 10 Ultrasonic Welding, including Welding Insertion Staking Spot Welding Swaging & Forming Cutting & Sealing 11 Vibration Welding 12 Laser Welding Ultrasonics is the most promising amongst these. nevik ultrasonics, 101-102, Eshan Plaza, Pipeline Road, Satpur, Nashik - 422 007 www.nevik.in [email protected] +91 253 235 1935 2 Ultrasonics is recommended when you wish to weld / assemble Most Thermoplastics, but especially, Engineering Plastics in Large numbers, to obtain Leak Tight Seals, with Consistent, Repeatable results Ultrasonics enhances quality, increases productivity, and reduces production costs. This book deals exclusively with the application of Ultrasonic Energy to Weld/ Assemble Thermoplastics. It attempts to demystify the subject, and provides basic information on weldability of materials, compatibility, interface joint designs, variables that affect the welding process, range of equipments available, troubleshooting, reputed sources of equipment, toolings and associated services. It is extensively illustrated and written in simple language for the lay user. It is intended to help you understand the process, appreciate its versatility, and benefit from its capabilities. A Glossary is added to help understand technical terms. Ultrasonics is the preferred method of assembly in today’s competitive world. nevik ultrasonics, 101-102, Eshan Plaza, Pipeline Road, Satpur, Nashik - 422 007 www.nevik.in [email protected] +91 253 235 1935 Chapter 1, Introduction 3 THE BENEFITS Ultrasonics is a clean, reliable, consistent and affordable process. It needs no pre-weld or post-weld operations. It uses no consumables of any nature, is user and environment friendly, and is a rapid, repeatable process. Invariably, ultrasonic assembly weld times are less than one second, far less than moulding times. Ultrasonics eliminates all subjective elements in the welding process, ensuring consistent quality. The consumption of energy is perhaps the lowest by any other process. Set up is quick and easy. Its versatility enables change over from one set-up to another within a few minutes. Toolings have long life, and need little or no maintenance. ` Heat sensitive materials can be ultrasonically assembled without fear of damage to parts or contents, as welding is achieved by limiting the heat to extremely localised areas. nevik ultrasonics, 101-102, Eshan Plaza, Pipeline Road, Satpur, Nashik - 422 007 www.nevik.in [email protected] +91 253 235 1935 4 SUCCESS Successful application of Ultrasonics in Joining Thermoplastics calls for a proper understanding of the process in terms of selection of materials, correct design of the weld interface, and use of appropriate toolings. The success or failure of an Ultrasonic application is determined at the design stage, and not on the shop floor ! Careful design is of utmost importance in ensuring a satisfactory weld. However, very little is known or understood about the Ultrasonic process, and it still remains a big mystery to many. So if you wish to switch to Ultrasonics -- successfully -- read on ! nevik ultrasonics, 101-102, Eshan Plaza, Pipeline Road, Satpur, Nashik - 422 007 www.nevik.in [email protected] +91 253 235 1935 Chapter 1, Introduction 5 APPLICATION AREAS Ultrasonics can be used on Injection moulded, Blow moulded and Extruded parts, as well as on Films, Fabrics & Sheets. It can be used to Join Thermoplastic to itself, or to assemble it to metal, paper, board etc. It can be used in intermittent or continuous modes. It can also be Automated. MARKET SEGMENTS Ultrasonics is popular in almost every market segment where large numbers need to be produced each day, to a high, consistent quality. Typical segments are Automotive Dashboard Instruments, Door Fittings, Interior & Exterior Trim, Glove Box Door, Bumper Fittings, Number Plates, Tail Lamps, Fuel Filters, Air Filters, Carburetor Floats, Brake Fluid Reservoirs, Overflow Reservoir, Air Diverter Valve, Sensors White Goods Refrigerators, Washing Machines, Dishwashers Electronics Dip Switches, Electrical Switches, Relays, Push Buttons, Mains Cables, Piezo Ringer Assemblies, Terminal Blocks, Connectors, Toggle Switches, PCB assembly staking, Audio & Video equipment nevik ultrasonics, 101-102,
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